Water spray assembly

ABSTRACT

A water spray assembly especially adapted for control of dust suppression in mining machines has a manifold with one or a number of nozzles mounted thereon. The manifold provides communication between the nozzles and a manifold inlet, the manifold inlet being adapted to connect to a supply of water. The manifold with one half of a quick connect coupling cooperates with a nozzle block having a bore sized to receive at least a portion of the manifold and the other half of the quick connect coupling. The use of quick connect coupling half with the block allows easy removal and insertion of the manifold.

This application claims priority under 35 USC 119(e) based onprovisional patent application No. 60/547,881 filed on Feb. 27, 2004.

FIELD OF THE INVENTION

The present invention is directed to a water spray assembly, and inparticular to a water spray assembly for mining equipment employing aremovable manifold to facilitate changing of spray nozzles in difficultto reach areas.

BACKGROUND ART

In the prior art, water sprays are used in mining equipment, especiallycoal mining equipment, to suppress dust and wet the mined product. Thesprays include nozzles, which are removably attached to manifolds orblocks, the blocks fixedly mounted to the mining machines at variouslocations. One problem with these sprays is plugging of the nozzles dueto the coal, coal dust, iron oxide, and other foreign matter. The spraysmust be continually cleaned for safety reasons and such maintenancereduces mining production. FIG. 1 shows a prior art spray system with ablock 1 mounted on a portion of a continuous mining machine 3. The block1 has a number of nozzles 5. A supply line 7 provides water to thenozzles for spraying purposes via a channel 9 within the block 1. Sincethese applications and types of mining machines are well known, afurther description is not necessary for understanding of the invention.

SUMMARY OF THE INVENTION

It is a first object of the present invention to provide an improvedwater spray assembly, particularly one that is adapted for use on amining machine.

Another object of the invention is a water spray assembly that permitseasy removal for cleaning and repair.

One other object of the invention is a water spray assembly thatutilizes a nozzle block and a manifold that is easily removed from thenozzle.

The invention allows the system to be continuously purged of pluggingcontaminants which otherwise would accumulate as occurs in prior artsystems.

Other objects and advantages of the present invention will becomeapparent as a description thereof proceeds.

In satisfaction of the foregoing objects and advantages, the presentinvention provides an improvement in water sprays assemblies,particularly those that are mounted to mining machines for wetting anddust suppression.

The water spray assembly comprises a manifold containing one or morespray nozzles mounted thereto. The manifold has a passageway, whichconnects inlets of the nozzles to a manifold inlet. The manifold inletis adapted to connect to a source of pressurized water via a hose or thelike.

The manifold is received and supported by a nozzle block or housing. Ina preferred embodiment, the housing is adapted to be attached to alocation on a mining machine to spray water as part of the miningoperation. One or more housings can be attached to the mining machine ina number of orientations and locations depending on the mining machineconfiguration. Of course, the housing and manifold could be adapted tomate with other components that utilize water sprays.

The nozzle block is configured to removably receive the manifold whileproviding one or more openings to allow the one or more spray nozzles ofthe manifold to direct the water spray in a given direction and/ororientation. By having the housing removably receive the manifold, themanifold can be easily removed when the one or more sprays becomeclogged. Another manifold with unobstructed nozzles can be inserted inthe nozzle block while the manifold with the clogged nozzles is cleaned.Moreover, the nozzle block can be positioned on the machine so that anoperator or user has ready access to the manifold for easy removal andreinstallation of another manifold.

The manifold can employ one or more nozzles and the nozzles can vary inspray pattern, flow rate, direction of spray and/or a combination ofthese variables. Virtually any nozzle can be employed in combinationwith the manifold.

The nozzles can be attached to the manifold by a threaded connection orany other connection as would be within the skill of the art.

The manifold shape is preferably circular in cross section ofcylindrical in shape. Other cross sectional shapes could also beemployed such as square, octagonal or the like.

The manifold material can be any material suitable for a particularapplication, but is preferably a material that is corrosion resistantwhile being capable of removably receiving the nozzles. One example is anylon block which can be machined with threaded opening for the nozzlesand water supply connection.

The water supply to the manifold can be provided by a hose having athreaded fitting which would connect to a threaded opening in themanifold. The connection between the manifold and hose could also be aquick connect fitting to facilitate removal of the manifold from thewater supply hose for nozzle cleaning and/or replacement.

The inventive water spray assembly can be used in methods of sprayingwater, particularly for dust suppression in mining environments such ascoal mines. The methods also involve the ability to remove the manifoldcomponent of the spray assembly for cleaning and repair, while leavingthe housing place.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made to the drawings of the invention wherein:

FIG. 1 shows a prior art water spray nozzle arrangement typically usedin mining machines;

FIG. 2 is a side view of one embodiment of the invention;

FIG. 3 is a perspective view of the nozzle block of the invention;

FIG. 4 is a side view of the manifold and the nozzle block in partialengagement;

FIG. 5 a is a back view of a nozzle block of a second embodiment of theinvention;

FIG. 5 b is an end view of the nozzle block of FIG. 5 a;

FIG. 5 c is a front view of the nozzle block of FIG. 5 a;

FIG. 6 a is a back view of a manifold to go with the nozzle block ofFIGS. 5 a-5 c;

FIG. 6 b is an end view of the manifold of FIG. 6 a;

FIG. 6 c is a front view of the manifold of FIG. 6 a;

FIG. 6 d is a sectional view along the line A-A of FIG. 6 a; and

FIG. 7 a is a perspective view of a nozzle block of the water sprayassembly;

FIG. 7 b is a perspective view of one-half of a quick connect fitting ofthe assembly;

FIG. 7 c is a perspective view of a pin used in the assembly;

FIG. 7 d is a perspective view of a manifold for the assembly;

FIG. 8 a is another perspective view of the manifold of the assembly;

FIG. 8 b is a perspective view of the nozzle block linked to one half ofthe quick connect assembly;

FIG. 8 c is another perspective view of the pin of the assembly;

FIG. 9 is a perspective view of the manifold partially inserted into thenozzle block;

FIG. 1 a is a perspective view of the nozzle block;

FIG. 10 b is a perspective view of the manifold connected to the onehalf of the quick connect assembly using the pin;

FIG. 11 is a perspective view of the completed water nozzle assembly;and

FIG. 12 is a cross sectional view of an alternative embodiment of themanifold of FIGS. 7-11.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention offers significant advantages over prior art water sprayheads and the like which are fixedly mounted on machines or otherequipment, particularly mining machines. The invention eliminates theneed to remove one or more nozzles in cramped areas or hard-to accessareas on a machine such as a mining machine for nozzle cleaning orreplacement. With the inventive water spray assembly, the manifold iseasily removed from the housing and replaced with another manifoldhaving clear nozzles. No or hardly any time is lost as part of thenozzle replacement operation, thereby avoiding losses in productivity.In addition, personnel are kept out of harm's way via ease of thereplacement procedure.

FIGS. 2-4 show one embodiment of the invention. FIG. 2 shows themanifold 21 having three nozzles 23. The nozzles 23 are threaded at 25to mate with complementary threaded portions 27 of the manifold. Themanifold has a passageway 29 interconnecting the nozzle channels 31 withan inlet 33.

The inlet is preferably threaded to receive a complementary threadedfitting 35. The fitting 35 interconnects the passageway 29 to a supplyhose 37 to supply pressurized water to the nozzles 23. The supply hose37 threads to the fitting 35.

Referring to FIG. 3, the nozzle block is designated as 41 and has a bore43 sized to receive the manifold 21. The block 41 also has a slot 45which allows travel of the nozzles when the manifold 21 is inserted intothe bore 43 of the block. The manifold 21 can friction fit into the bore43 or be locked in with some type of a locking mechanism, e.g., a pin, adetent mechanism or the like.

The slot 45 of the block can be sized as shown in FIG. 4 so that thenozzles are recessed from the block outer surface. In this way, thenozzles are more protected from impact from coal, coal dust, and othermachinery, thereby lessening the chances of nozzle plugging or damage.Of course, the nozzles could be flush with the outer surface of theblock or even extend outwardly therefrom is so desired.

The block 41 also can have a cutout 47 which is sized to accommodate theconnection between the water supply and the manifold 21. The cutout 47is shown at about a 90° from the slot 45 but other orientations could beused, e.g., the slot 45 could be opposite the cutout 47. In otherembodiments, the cutout could be optional, e.g., the fitting 35 was nota 90°-type fitting but was aligned with a longitudinal axis of themanifold.

FIG. 4 shows a partial insertion of the manifold 21 into the block 41.

FIGS. 5 a-c and 6 a-d show other embodiments of the block and manifold.The FIGS. 5 a-5 c embodiment shows the block with a threaded portion forconnection with the manifold. FIG. 5 a shows a back view of an exemplary2.5″ O.D.×1.5″ I.D. steel tube nozzle block 60 showing two end slots 61,and 63. The end view of FIG. 5 b shows the slots 61 and 63 arranged at a90° angle. The slots 61 and 63 are preferably 1.5″ long, and the end 66of the tube has a threaded interior portion 68. FIG. 5 c shows a thirdslot 65, which runs almost the length of the tube. The end 70 oppositeend 66 has a chamfered edge 72, preferably a ⅛″ chamfer. Each slotpreferably terminates with a ⅜″ radius shape.

The FIGS. 6 a-6 c show a manifold 21′ with an inlet 71 and outlet 73.The manifold is preferably a 1.51″ O.D. nylon rod. This differs from theFIG. 2 embodiment wherein the manifold has only an inlet. The manifold21′ preferably has a 4.5″ deep bore with an opening tapped ¾″ deep to ½pipe. The outlet 73 is drilled and tapped to ½″ pipe. FIG. 6 b shows therelationship between the inlet 71 and the outlet 73, with FIG. 6 cshowing the channels 75 which correspond to the channels 31 of FIG. 2.FIG. 6 d shows a sectional view wherein the relationship betweenchannels 75 and the outlet 73 are shown. The channels are preferablydrilled and left hand tapped to ¼″ straight pipe, typically in fourplaces. In the embodiment shown in FIGS. 5 and 6, the assembly can bepositioned so that water entering inlet 71 can exit outlet 73 and bedirected to other sprays or the like.

Although not shown, the manifold 21 could also have an outlet so that itcould be connected to another manifold for a serial hook-up of nozzles.

The manifold could also employ a puller bar on one end thereof tofacilitate removal from the block.

The block can be mounted by any means such as welding, fasteners, or thelike, and can be either fixedly mounted are adjustably mounted.

FIGS. 7 a-11 show another embodiment of the invention wherein themanifold has one half of quick connect fitting on one end and the blockhas the other half of the quick connect fitting associated with it anddisposed at an end thereof. This arrangement is much more advantageousthat the arrangement shown in the previous embodiments because the blockand one half of the quick connect coupling can be secured at a desiredlocation in a more permanent fashion, and only the manifold needs to beremoved to clean or replace the spray nozzles.

Referring to FIGS. 7 a-7 d, the entire system is designated by thereference numeral 100. The system further includes a manifold 101 withnozzles 103, and a quick connect male fitting half 105 of a quickconnect coupling that extends from manifold end 118. The manifold 101 issimilar to that shown above with a bore providing communication betweenthe openings in the nozzles 103 and source of water connected to thequick connect male fitting 105. The nozzle block is designated by thereference numeral 109, with the slot 111 for the nozzles and bore 112,and openings 113 for locking the manifold in place using the pin 115.The block 109 is sized so that the pin arms 117 fit around the recess107 at the end of the manifold to hold the manifold in place. The otherhalf of the quick connect coupling as the female fitting is designatedby the reference numeral 119. The female fitting 119 has a first opening123 to receive the male end 125 attached to the end 118 of the manifold.The fitting 119 also has an inlet 127 to provide communication betweenthe manifold and a source of water for spraying.

FIGS. 8 a-8 c show the female quick connect fitting 119 attached to theend 131 of the block. Although not shown, the block end 131, see FIG. 7a, has an opening, which aligns with the opening 123 in the fitting 119so that the end 125 of male fitting 105 can connect with female fitting119.

FIG. 9 shows the manifold 101 partially inserted into the bore 112 ofthe block 109, with the pin 115 partially entering the openings 113.Notice that the nozzles 103 align with the slot 111.

FIGS. 10 a and 10 b show quick connect fittings 105 and 119 connectedoutside of the block 109 to more clearly show the engagement between thepin arms 117 and the recess 107 on the male fitting 105.

FIG. 11 shows the system completely assembled wherein the male fitting105 and female fitting 119 are joined so that the nozzles 103 are incommunication with inlet 127 of the fitting 119 so that water can besupplied to the nozzles 103 for spraying.

The manifold in the FIG. 7 embodiment with the one or more nozzles hasthe quick connect fitting aligned with an axial bore of the manifold,unlike the embodiments shown above, wherein the manifold includes anelbow so that an axis of the quick connect fitting is perpendicular tothe axial bore of the block. In addition, the block is open on each end,one end allowing insertion and removal of the manifold, with the otherend being open so that the quick connect fitting half on the manifoldcan engage the other half of the fitting which is located adjacent theother open end of the block.

The invention entails both the combination of the block and themanifold, as well as the manifold itself as uniquely adapted tointerface with the block. While the male fitting is shown on themanifold with the female fitting associated with the block, the nozzleand manifold could be sized so that the manifold would contain thefemale fitting with the male fitting associated with the block. However,it is preferred that the manifold contain the male fitting since thealternative arrangement requires the nozzle bore and manifold to belarger to handle the female fitting.

The attachment between the block and fitting can be done in any manner,for example, welding or mechanical attachment. As an alternative, theblock could be attached to another structure, with the quick connectfitting placed in the proper position with respect to the block andattached to other structure as well, thus leaving the block and fittingunattached. Preferably though, the block and quick connect fitting areattached together.

Another aspect of the invention entails providing a wire mesh basketwhich fits over the inlet at the male fitting end 125 that receiveswater for spraying. The wire mesh basket acts as a filter to preventparticles from passing through the manifold and clogging the nozzleopenings. The basket is attached to the male end in such a way so thatthe quick connect fitting can still function, but debris in the waterbeing supplied to the manifold is filtered prior to entering thenozzles. A cross section of the end 125 of the manifold of FIG. 7D isshown in FIG. 12 as one example of the mesh basket embodiment. Thebasket is designated by the reference numeral 130, and has a collar 131that interfaces with a lip 133 formed on an interior of the inlet 135 ofthe male fitting end 125. The lip can be formed by boring out the inletto a diameter sized to receive the collar 131 of the mesh basket 130.The depth of the bore is made to match the height of the collar 131 sothat when the basket 130 is installed, the basket top is flush with theend face of the male fitting end 125. The mesh part 137 of the basket130 extends within the manifold inlet 135, so as to prevent debris fromentering the inlet 135 and clogging the nozzles 103, see FIG. 7D. Thewire basket collar 131 can be distorted in one mode to snugly fit intothe inlet 135 so that fasteners are not required. However, fastenerscould be employed to keep the basket in place, if desired. Of course,other ways as would be known to those of skill in the art can beemployed to combine the basket with the male end 125. It should be alsounderstood that the mesh basket could be employed on the embodimentshown in FIGS. 1-6, and particularly in conjunction with the threadedfitting 35. The same design could be employed on fitting 35 wherein theinlet would be modified to receive the wire mesh basket.

While the mesh size of the basket can vary depending on the nozzle sizesand target impurity sizes, a preferred mesh size of 30 mesh, althoughsmaller or larger meshes, e.g., 18, 20, and 24, 35, 40, 50, 60 and soon, can be employed.

As such, an invention has been disclosed in terms of preferredembodiments thereof which fulfills each and every one of the objects ofthe present invention as set forth above and provides new and improvedwater spray assembly and its use with mining machine.

Of course, various changes, modifications and alterations from theteachings of the present invention may be contemplated by those skilledin the art without departing from the intended spirit and scope thereof.It is intended that the present invention only be limited by the termsof the appended claims.

1. A water spray manifold comprising a manifold having an axial bore andat least one nozzle mounted thereon, the manifold providingcommunication between the one nozzle and a manifold inlet, the manifoldhaving on an end thereof one half of a quick connect coupling, with thefitting axially aligned with the axial bore.
 2. A water spray assemblycomprising: a) a manifold having an axial bore and at least one nozzlemounted thereon, the manifold providing communication between the onenozzle and a manifold inlet, the manifold having on an end thereof onehalf of a quick connect coupling, with the fitting axially aligned withthe axial bore; b) a block having a bore sized to receive at least aportion of the manifold, the block adapted to be mounted for directingthe at least one nozzle in a particular direction, and being open onboth ends; and c) the other half of a quick connect coupling alignedwith an open end of the block bore, and adapted to connect to the onehalf of the quick connect fitting on the manifold, the other halfincluding an inlet to provide communication between a source of waterand the at least one nozzle.
 3. The assembly of claim 2 in combinationwith a mining machine.
 4. The assembly of claim 2, wherein the block hasa slot in communication with the bore to allow the least one nozzle thatextends outwardly from the manifold to travel in the slot when themanifold is inserted into the bore.
 5. The assembly of claim 4, whereinthe slot is sized so that the at least one nozzle is recessed from anouter surface of the block.
 6. The assembly of claim 2, wherein themanifold is held in place in the block using a pin.
 7. A method ofreplacing nozzles in a water spray assembly comprising: a) inserting themanifold of claim 1 into a block adapted to receive the manifold andsupply water thereto, the manifold having the at least one nozzle inclean or new form, and/or b) removing the manifold from a block adaptedto receive the manifold and supply water thereto when the at least onenozzles becomes inoperable.
 8. In a method of at least suppressing duston a mining machine using water sprays, the improvement comprising: a)providing a water spray assembly of claim 2; and b) spraying watertherefrom for said dust suppression.
 9. The method of claim 8, whereinthe water is sprayed on coal mined by the mining machine.
 10. Themanifold of claim 1, wherein the manifold is cylindrical in shape. 11.The manifold of claim 1, wherein the one half of the quick connectcoupling has a groove adapted to receive a retaining pin intended tokeep the manifold in a nozzle block.
 12. The manifold of claim 11,wherein the groove is positioned between the one half of the quickconnect coupling and the at least one nozzle.
 13. The manifold of claim1, further comprising a wire mesh basket covering the manifold inlet.14. The manifold of claim 11, further comprising a wire mesh basketcovering the manifold inlet.